Engineering at Coal Mines

Detailing the installation of mechanical equipment and conveyor structures is one of the final steps for completing a maingate drive-head design. Installations designed by Orana Engineering for Glencore’s Oaky No.1 underground coal mine included detailing drive arrangements, transfer stations, take-up units, maintenance equipment and the overhead structures supporting the carry belt.

Mechanical design must consider a number of factors, including meeting the required operating capabilities, allowing for unimpeded access along travel roads and maintaining minimum belt curves. Often equipment is relocated from previous installations with minor modifications in transfer angle and number of drives. Orana Engineering has developed unique methods for completing this type of design, enabling us to keep total costs down for our clients.

The CHPP at Oaky Creek Coal utilises a Yokogawa Distributed Control System for control and monitoring of their operation. The system incorporates Yokogawa’s OPC server and Exaquantum data historian. OCC utilises multiple Programmable Logic Controllers for specific operational purposes, with a number of PLC's interfaced back to the DCS for control and monitoring functions.

Since 2005, Orana Engineering has provided 24/7 support for Oaky Creek’s control system. Day to day support is provided by remote access, which is cost effective and highly responsive. Additionally, onsite support for hardware solutions and commissioning of larger projects is provided as required.

To increase productivity and maintain compliance with legislative standards, Glencore Oaky Creek Coal employed the services of Orana Engineering to design and manage the electrical aspects of an upgrade to their existing sewage treatment plant.

The project was managed on-site by others, with Orana Engineering providing electrical engineering, design, project management and construction / commissioning assistance.

Upon completion of installation, Orana Engineering updated all drawings to reflect any changes made, thus providing Glencore Coal with as-built drawings which will make any future maintenance or fault-finding work more efficient and cost effective, as well as providing legislative compliance.

Engineers at Glencore’s Oaky No. 1 underground coal mine engaged Orana Engineering to determine civil work requirements to effectively utilise drive-head equipment in newly mined chambers for conveyor installations.

On completion of chamber mining, finished surfaces (rib and floor) may require modification for installation of the conveyor drive-head equipment. The civil design must determine concrete grades for drainage, safe access and reinforcing for conveyor equipment, while minimising trimming and concrete required.

Manipulating “as-cut” survey data using AutoCAD, Orana Engineering design staff could accurately determine where equipment might be installed with minimal trimming and concreting. A drawing set was produced detailing civil aspects of the conveyor design, including chamber trimming, equipment mounting locations, configuration of reinforcing and relative concrete levels.

Vale at Carborough Downs Coal Mine required quantifying of current and possible future capacities of product conveyors at their coal processing plant in Central Queensland and high level recommendations to achieve increased plant tonnages.

Orana Engineering completed an initial site visit to gather the necessary information for a review of each of the conveyors.  Engineering checks were completed to identify bottle-necks in the conveyor design such as motor power, drive equipment, belt curves, GTU mass, belt speed, belt capacity, belt tensions and electrical supply. 

Orana Engineering issued a detailed report at completion of the study and provided concept level equipment modification recommendations for tonnage ranges advised by Carborough Downs Coal Mine.

For site consistency of electrical design and installation standards and compliance with Australian standards and legislation, Glencore Oaky Creek Coal engaged Orana Engineering to prepare new site electrical specifications. The scope combined existing site specifications and practices and, where applicable, incorporated them into the new specifications. These specifications included:

• Electrical Design
• Electrical Installation
• Preferred Electrical Equipment List
• Site Equipment Numbering
• Drawing Management

Orana Engineering’s extensive knowledge of Queensland mine sites and long-standing experience at Oaky Creek enabled specifications to be produced cost effectively and fully inclusive of site specific details. Orana Engineering continues to maintain these documents for Oaky Creek Coal, ensuring that latest versions are readily available to site personnel via Oaky Creek’s drawing management system.

Oaky Creek Coal uses an onsite reverse osmosis plant to provide treated recycled water to various site operations. An opportunity was identified to use this recycled water for supply to critical equipment such as horizontal belt filters, thereby improving equipment water quality, reducing equipment downtime and lowering maintenance requirements.

Orana Engineering reviewed the performance of two existing boost pumps intended to provide high pressure treated water to a new horizontal belt filter. Hydraulic modelling was performed to predict future demand and thus determine the suitability of the existing pumps for use in the new application.

Orana Engineering also prepared a control philosophy for use by systems engineers to ensure safe operation of the pumps under all operating conditions.

Carborough Downs Coal Mine is an underground operation utilising conveyors to transport mined coal to the surface for processing. As operations progress and new longwall headings are mined, new conveyor installations are also required.

Carborough Downs engaged Orana Engineering to complete a mechanical arrangement design for configuration of conveyor equipment. The design had to consider several factors, including meeting required operating capabilities, ensuring unimpeded access along travel roads and maintaining minimum belt curves.

Using AutoCAD, Orana Engineering developed a mechanical design that met client constraints and constructability requirements. From the design, a drawing set was produced detailing mechanical aspects of the conveyor design, including equipment configuration, and extensive details for selection and installation of conveyor structures, whilst minimising curves.

Carborough Downs is an underground operation utilising conveyors to transport mined coal to the surface. As new longwall headings are mined, new conveyor installations are also required. During installation of conveyors in an underground environment it is vital that the civil design is detailed accurately as this is the basis for locating and installing conveyor equipment.

Orana Engineering was engaged to complete this design and used AutoCAD to develop a civil design that met the client’s constraints and constructability requirements. From this design Orana Engineering produced a drawing set detailing civil aspects of the conveyor design, including floor / rib trimming, equipment hold-down details, configuration of concrete reinforcing and overall grade of concrete.

Carborough Downs Coal Mine is an underground operation utilising conveyors to transport mined coal to the surface for processing. As operations progress and new longwall headings are mined, new conveyor installations are also required.

Orana Engineering was engaged to design a new longwall drive-head chamber and conveyor installation, initially providing a drawing set detailing required drive-head chamber dimensions to suit the conveyor installation.

Using AutoCAD, a civil design and conveyor equipment arrangement was produced. The conveyor design had to consider several constraints, including available equipment, transfer tie-in to existing trunk conveyor, maintenance access, drainage, minimum clearances and belt curves.

Upon layout approval, AutoCAD drawings were produced detailing civil and mechanical design aspects, enabling site engineers to complete installation with efficiency while ensuring regulatory compliance.

Mining millions of tonnes of material requires significant infrastructure and planning. Orana Engineering has been engaged on multiple occasions at Glencore’s Oaky No. 1 underground coal mine, to design new conveyor drivehead chambers to install equipment for longwall mining.

Using the client’s existing mine plan, Orana Engineering design drafting personnel worked in tandem with engineers to assess required chamber locations and dimensions, with consideration to the size and orientation of equipment to be installed and minimising the material to be excavated.

An AutoCAD drawing set was produced detailing the extent of mining required along with an overlay showing future equipment installations, enabling the client to efficiently complete chamber mining with a design suitable for future installations and minimal rework.

Carborough Downs is an underground operation utilising conveyors to transport mined coal to the surface. As new longwall headings are mined, new conveyor installations are also required. Orana Engineering was engaged to complete a drive-head chamber design, ensuring adequate sizing for installation of conveyor equipment.

During initial mining of the chamber, a coal seam fault line was discovered. Carborough Downs requested that Orana Engineering develop a chamber design that maximised product mined through the fault area, while working within conveyor installation constraints. Using AutoCAD, Orana Engineering produced several design options and sketches for client approval and reference during mining processes.

Orana Engineering provided final chamber excavation drawings, which were developed into mine designs and sequence plans, by site mining engineers.

At the completion of tailings pumping upgrades of the main CHPP and Module 4 CHPP at Oaky Creek Coal, Orana Engineering received as built drawings from site and was requested to make electronic revisions for upload into the client’s Drawing Management System.

Over 80 drawings had received red pen site mark-ups indicating either that the design had been constructed as per the drawings, or highlighting design changes made during the construction phase of the project. Orana Engineering reviewed these mark-ups and formally revised all drawings to as built status, incorporating the site mark-ups.  

The final set of drawings was uploaded to the client’s Drawing Management System ensuring site personnel had access to the latest as built drawings.

Orana Engineering was engaged by Glencore to design and install a detailed arrangement of tripper drives, brakes, pulley frame and load station for the MG32 conveyor at its Oaky No.1 underground coal mine.

Mechanical design considerations included operating capabilities, unimpeded travel road access and minimum belt curves. The design was dependent on the civil installation previously detailed by Orana Engineering. Often equipment is simply re-located from previous installations with minor modifications. Orana Engineering has developed unique methods for completing this type of design efficiently and at reduced cost to our clients.

AutoCAD was used to develop a mechanical design, from which a drawing set was produced that detailed out the mechanical aspects of the tripper installation

BMA Gregory Crinum engaged Orana Engineering to perform an audit and inspection of the Crinum underground mine surface fire water system with respect to providing adequate pressure and flow for the Crinum North conveyor system and stockpile conveyor.

Orana Engineering completed a site inspection and audit against the design drawings, with site-verified information then used for compliance assessment in line with Australian Standards. The audit included in-depth assessment of the fire water system to Australian, BMA and site Fire Management Standards. Hydraulic modelling of the fire system was also undertaken to validate existing pressure measurements.

Orana Engineering was able to make recommendations regarding compliance and system hydraulic performance, which assisted BMA in improving system capacity.

Orana Engineering was engaged by Oaky Creek Coal to assist in design and construction of onsite camp accommodation, including an HV substation for power and potable water supply.

The brief included mechanical, electrical and control systems design, drafting and engineering for the project.  Deliverables included scope of works, construction drawings, functional specification, drawing and equipment registers, commissioning and operating spares lists and equipment and instrument data sheets.

Orana Engineering provided PLC configuration and commissioning assistance for pump control, acted as Client Representative during construction, managed onsite commissioning of the system, and provided a handover to operations for implementation.

Operation & Maintenance Manuals for potable water storage and the HV substation were provided upon completion.

The purpose of the Reagent System Upgrade at Oaky Creek was installation of new reagent storage tanks, discharge / delivery pumping systems and automated flow control distribution manifolds for the delivery of each reagent to the nominated process connections.

Orana Engineering performed mechanical, electrical and control systems design, drafting and engineering for the project.  The primary deliverables included scope of works, construction drawings, functional specification, BOM, spares lists and equipment / instrument data sheets. 

Orana Engineering managed the onsite commissioning of the system and provided a system handover to operations for implementation. An Operation & Maintenance Manual and Hazardous Area Dossier were provided on project completion.

Glencore’s Newlands Open Cut Coal Mine was investigating methods to update bunding for a 2 million litre diesel storage tank and engaged Orana Engineering to assess the existing bund while also considering requirements for a future fuel farm and compliance with Australian Standards.

Orana Engineering reviewed client-provided documentation and information gathered from site including drawings and survey data of the existing earth bund and details of underground services. Assessment of suitable liner options and an evaluation of the existing earth bund for necessary repair was also conducted along with considerations for tie in of the bund liner to existing structures. Orana Engineering delivered a file note for the site Project Manager to review compliance options.

At the request of Glencore’s Collinsville Open Cut Mine, Orana Engineering provided a concept design for upgrade of aging infrastructure associated with the sites anti-pollution pond. 

Orana Engineering provided a detailed design for installation of permanent handrail and barrier systems along the access pathway to mitigate hazards.  The walkway bridge was identified as having inadequate support structure and was included in the proposed design, along with relocation of the existing pump pontoon and level sensors.

Orana Engineering design drafters produced 3D modelling for the installation which was provided to the client along with a general arrangement drawing of the new pontoon access, a fabrication detail drawing of the steelwork support and a civil and access ramp detail drawing, with RPEQ supervision.

Glencore’s Collinsville Open Cut mine utilises sprinklers to partially destroy Acid Mine Drainage (AMD) water generated. Existing sprinklers were effectively moving the AMD water, but at a slow rate. Orana Engineering was contacted for assistance in designing a system to increase the existing sprinkler arrangement from 67 to 200 units, capable of dewatering up to 9.45ML per day, while utilising a minimum of pumps and nozzles.

Orana Engineering mechanical and electrical engineers gathered data and undertook hydraulic modelling in developing a sprinkler design to increase water surface area while decreasing maintenance and failure rates of existing nozzles.

3D modelling of the design was presented to the client along with RPEQ supevised detail design drawings.

The CPP chain feeder at Glencore’s Clermont Coal Mine required repair and the assistance of Orana Engineering was sought with development of an appropriate methodology and associated detailed design drawings.

Steel plates had been installed to cover the chain feeding system, which over time had been degraded by the dozer feeding the system chipping away at concrete footings. This caused exposure of the steel plate edge which subsequently caught on the dozer bucket. The result was a build-up of material around the chain, causing downtime to reinstate plates and clean up material.

Orana Engineering’s basis of design was for repair of the existing reclaim feeder concrete and development of suitable protection to reduce future wear damage and deterioration from dozer contact. Existing concrete footing drawings were revised to reference new concrete and steel detail and then issued for client review prior to finalising, with RPEQ supervision.

The CHPP Maintenance Superintendent at Glencore’s Collinsville Coal Mine sought the assistance of Orana Engineering in developing Work Instructions for various maintenance processes carried out within the CHPP. 

Two Orana Engineering Mechanical Engineers were assigned to attended site on multiple occasions during scheduled plant shutdowns to review processes and either update existing or generate new Maintenance Work Instructions for multiple functions and locations within the CHPP.

Finalised Work Instructions were subsequently presented to the client for final approval prior to incorporation / upload into Collinsville’s resource library. 

Glencore Coal Collinsville sought assistance from Orana Engineering in assessing multiple monorail designs within the CHPP area. The design review was to determine compliance with Australian Standards, including analysis of the structural capacity of each monorail, taking details from design drawings, 3D scans of the plant and physical measurements. 

Fifteen monorails in total were assessed via visual and non-invasive means to determine their general state. Photos were cross-referenced with 3D scan data of the plant and existing structural drawings, with a structural assessment completed on all monorails to AS1418.18 using SpaceGASS and spreadsheet calculations.

Deliverables to the client upon conclusion of the study included a summary of design review results and recommendations for remedial action. Results from the assessment allowed updated certified as-built drawings of each monorail to be produced.

Orana Engineering was requested by the CHPP Manager Capital Projects at Glencore’s Collinsville coal mine to provide engineering and scoping assistance with respect to the mine’s underground water service repair and upgrade scope of work.

A member of the Orana Engineering mechanical engineering team attended site to liaise with onsite stakeholders, operators, plumbers and surveyors and to gather information on raw water and potable / fire water supply issues being experienced.

Upon return from site, a high-level engineering review was conducted along with detailing of raw water and potable / fire water scopes.  Basic hydraulic modelling was also carried out to identify pressure spike issues and water hammer.  Following review completion, the client was provided with a basis of design and a summary of Orana Engineering’s findings and recommendations.

Orana Engineering provided client engineer and project management support for the design and installation of a new product coal sampler at Glencore's Collinsville Mine CHPP.  The scope also included civil engineering support and design drafting for the concrete footings which were out of scope for the sampler supplier.

Orana Engineering's project manager provided onsite support as required to deliver the multidisipline design and installation taking into account the requirements of site stakeholders in the brownfield site. 

Glencore’s Newland Coal operation required removal of three Redispan conveyor modules at the tail end of its CV805 conveyor, leaving the head end modules in place. Assistance was sought from Orana Engineering in evaluating the stability and suitability of the head end support structure in withstanding the longitudinal loads of the conveyor.  

Orana Engineering conducted a high level inspection and provided structural engineering advice as to the optimal lifting methodology to prevent overloading of the conveyor supports and pins as well as identification and recommendation of necessary limitations such as wind considerations and applicable exclusion areas.  A review of the linkage of each remaining longitudinal brace was also undertaken to evaluate the stability of sections prior to their removal.

Upon conclusion, a letter of recommendation was presented to the client detailing outcomes of the Redispan structural review and installation, and providing engineering advice for the demolition works.

Glencore's Collinsville Coal Mine engaged Orana Engineering to develop a deconstruction safe work methodology for demolition and deconstruction of the CBN302 reject bin, along with appropriate risk assessment documentation based on the deconstruction methodology. 

Key considerations were ensuring that the bin and structure supporting the conveyor head end were maintained in a safe and stable condition during deconstruction and that the risks of stored energy in the curved bin shell plates was managed through the steel thermal cutting process (avoiding steel plate spring-back hazards).

Orana Engineering’s basis of design determined the necessary steps to safely remove the redundant CBN302 reject bin.

Detailed design and engineering provided by Orana Engineering included 3D modelling of the reject bin and structural steelwork to assist in preparing the methodology images.

The CHPP Structural Supervisor at Glencore’s Collinsville Coal Mine requested the services of Orana Engineering in completion of a structural review and provision of a replacement methodology for the CCV101 Trestle Clevis Plates.

Orana Engineering’s consultation included a structural review of documents and existing drawings, identification of load-bearing elements and weak points, analysis of existing design and indication of necessary modifications. Additionally, the review included development of a strengthening plan and methodology utilising temporary bracing and support systems to lift the structure for trestle clevis plate replacement and avoid working under suspended loads using props.

Outcomes from the project included a letter of recommendation with instructions for the trestle clevis plates replacement works, including notes and methodology, mark-ups of site photos and drawings to illustrate the proposed replacement methodology.

Orana Engineering was consulted by Glencore’s Collinsville mine to assist with an upgrade of its CHPP washdown water distribution system.  The CHPP clarified / raw water is supplied from either an anti-pollution pond or the raw water Sunwater pipeline, with the wash water distribution network delivering water to the yard area, CHPP washdown sprays, lime / flocculant dosing or conveyors for spray bars and washdown.

Following hydraulic modelling, Orana Engineering’s mechanical engineers delivered a design with improved flow and pressure, (increasing capacity from 375 to 700 cubic meters per hour) while structural engineers produced SpaceGASS modelling of pipe supports and 3D modelling of the discharge structural steel pipe rack. Additionally, a Functional Specification or Function Description was produced for integration of the design into the plant's control system.

Project deliverables included an Equipment Register, Scope of Supply, detailed Construction and Installation Scope of Work for Tender, Functional Description and detailed design drawings.

Anglo American’s Moranbah North CHPP operations personnel contacted Orana Engineering to investigate problems with low compressed air pressures and air flow rates. There were additional concerns regarding compressor reliability associated with the operation of equipment, valves, tooling, maintenance and instrumentation.

Orana Engineering conducted an onsite investigation which included preparing as-built drawings of the high-level compressed air distribution network within the CHPP.  A review of historic transmitter data for the system was also carried out to identify issues and bottlenecks. System performance was also reviewed against site-checked pressures and engineering flow rate and pressure loss.

Upon conclusion of the investigation a summary of findings and recommendations was presented to the client encompassing as-built drawings, calculations, a summary of works and recommendations for resolution.

Anglo American Grosvenor Mine sought the assistance of Orana Engineering in developing check sheets for reference by site personnel during underground conveyor commissioning processes.

Firstly, Orana Engineering produced an extensive Inspection & Test Register covering the civil and mechanical components of the various conveyor systems on site. The Register provided a breakdown of all system areas required to be covered by the commissioning check sheets.

Close communication between site and mechanical personnel from Orana Engineering ensured a comprehensive list of inspection and testing tasks was produced, covering all of the checks to be undertaken during conveyor commissioning.

From the approved Inspection & Test Register, approximately 190 individual check sheet templates were issued for review and approval by site management prior to use by mine personnel during the commissioning process.

Orana Engineering was approached by Glencore’s Oaky Creek Coal CHPP personnel to supply a cost estimate for development of modified winch systems for its CV15 and CV16 take-up towers.

The scope of work included provision of mechanical, structural and electrical engineering and design drafting for inclusion of electric take-up winches to facilitate lowering of conveyor counterweights during maintenance activities.

Structural and civil checks were conducted to account for expected force changes caused by additional sheaves and electrically driven winching effects on the structures when compared to the existing gravity take-up applications.  The installation was configured and commissioned into the DCS control system by Orana Engineering's control systems engineers.

In addition to mechanical and electrical detailed design drawings, Orana Engineering provided equipment recommendations and specifications, bill of materials and a Safety In Design Report upon finalisation of the design development cost estimate.

Orana Engineering was contacted by Glencore for assistance in determining ground anchoring of three mobile crib huts at its Rolleston Coal Mine. The objective of Orana Engineering’s investigation was confirmation of applicable regional wind loads on each structure and requirements for external hold-downs with respect to sliding and overturning forces.

To assess anchoring options, calculation and analysis of wind forces on the mobile crib huts was performed using AS/NZS1170.2 for loading with various earth anchor types evaluated while also taking into consideration soil properties and ground compaction.

Based on structural engineering principles and calculations, and in consideration of Australian Standards and industry best practice, it was determined that all the mobile crib hut structures required anchoring to prevent sliding or overturning. Recommendations for the most appropriate type of ground anchor, along with general stipulations for application and installation of the these, was documented and presented to the client upon conclusion of Orana Engineering’s evaluation.

At the request of Glencore’s Collinsville Open Cut Coal Mine, Orana Engineering personnel attended site to perform a visual inspection on the CCR106 Abon Crusher following failure of the gearbox-to-crusher mounting studs.  

The focus of the inspection was assessment of damage to impacted structural steel members on the crusher floor which had resulted from gearbox movement during the failure, and to troubleshoot the reason for the stud failure.

A summary of observations and supporting photos gathered during the inspection was compiled for presentation to the client. In addition, Orana Engineering provided a professional opinion regarding possible scenarios leading to failure of the mounting studs and offered recommendations for additional checks on the integrity of the crusher infrastructure.

Process Engineering personnel at Glencore’s Collinsville Coal mine contacted Orana Engineering for engineering support on various projects associated with an upgrade of the piping in its ultrafine circuit. These included incorporation of tee-offs to in situ lines, and additional pipe runs. 

Orana Engineering utilised existing 3D scan data to model a new pipe route and to provide concept general arrangement drawings to the client.  With this information site personnel had sufficient data to liaise with vendors regarding new equipment selection.  

Orana Engineering’s estimate also allowed for detailed design of RPEQ supervised drawings to allow the piping to be fabricated and installed. 

Additionally, Orana Engineering conducted a structural assessment of the horizonal belt filter (HBF) to support a proposed viper roller unit.

A filter press initially planned for Glencore’s Clermont Coal Mine was relocated for installation at Collinsville Coal Mine in a trial capacity to assist in reducing the amount of tailings produced from the wash plant. 

Orana Engineering was engaged to provide engineering and drafting support for the filter press installation scope of work, to assess suitability of the Clermont detailed design for construction at Collinsville and to plan and implement arrangements for the installation.

Considerations to ensure a smooth installation at Collinsville included concrete design and a structural analysis. Calculations were also undertaken to determine design wind and earthquake loads for the site to Australian Standards AS/NZS1170.2 and AS1170.4.

Orana Engineering design drafters produced a new site plan showing set-out of the filter press slab with new and existing underground services detail incorporated, with RPEQ Supervision. 

The main plant raw water boost pumps at Glencore’s Oaky Creek Coal were supplied via a starter panel which required replacement due to water inundation and for improved functionality, reliability and compliance.

At the client’s request, Orana Engineering provided a report outlining preliminary design checks completed and provided a high-level summary of installation works required to the pump starter panel for a new MCC already on site.

Multiple upgrades were required to electrical equipment as well as associated civil / structural works. A preliminary concept sketch was prepared giving an overview of proposed upgrades. An Orana Engineering Electrical Engineer was appointed to assist with onsite commissioning of the raw water boost pumps and to provide offsite assistance with DCS configuration.

Deliverables to the client included electrical engineering and design drawings to IFA/IFC, a scope of work and a bill of materials.

Orana Engineering undertook an audit of ladders, steps and walkways associated with the Collinsville Open Cut CHPP gravity take-up (GTU) access platforms. A desktop audit was completed from photos and technical information gathered on site and with reference to AS1657 "Fixed Platforms, Walkways, Stairways & Ladders - Design, Construction & Installation" and the client's own standard for ladders, steps and elevated walkways.

At the conclusion of the audit, a letter of recommendation was provided to Collinsville Open Cut, documenting audit findings, cross referencing photos and detailing remedial action necessary for compliance. Signage requirements were also determined within the scope of the audit and included in audit recommendations.

Glencore’s Hail Creek Coal Mine engaged Orana Engineering to develop the engineering design for a stand to elevate a 1,000 litre IBC from ground level, enabling the content to gravity feed to the pump suction during a major upgrade project.

Design considerations by Orana Engineering included the process and materials relevant to the IBC location, raw material requirements and painting specifications based on site standards, positioning and fit of the IBC with existing equipment and infrastructure once elevated on the stand.  Height requirements for gravity feed to pump suction connection and allowance for differential grouting of feet to account for concrete falls were also taken into account.

Orana Engineering design drafters generated a 3D model of the proposed design using AutoCAD Advance Steel for client review before developing a Navisworks Model of the IBC stand and completing engineering checks for load. 

Final deliverables to the client included arrangement and fabrication detail drawings of the stand with RPEQ supervision.

Orana Engineering was contacted by Glencore’s Oaky Creek Coal Mine to undertake a structural review of lighting towers situated at the Tieri township sporting oval. Existing tower bases had been buried for approximately 20 years and were displaying evidence of corrosion to anchor bolts and baseplates.

Orana Engineering conducted a review of client-supplied documentation and photographs and gathered additional information to determine repair requirements.  Following the review, a letter of recommendation was provided to the client outlining repairs required for continued operation of the lighting towers, with RPEQ structural supervision.

Additional support was provided by Orana Engineering with a further review of lighting towers within the Tieri Aquatic Centre and Shopping Centre. In this instance Orana Engineering was also able to capture 3D data from light poles using its Faro 3D laser scanner. The client was presented with recommendations for tests or further analysis required.

Deficiencies with existing and Life of Mine (LOM) pit compressed air systems at Xstrata Coal’s Oaky No.1 Underground Coal Mine had been resulting in numerous production delays. Orana Engineering was engaged to investigate, analyse and provide delivery strategies for ensuring acceptable air pressures and flow rates were achieved for remaining mining activities within the site LOM Plan. 

Considerations for improvement included additional compressors and piping system changes where required to achieve improved compressed air flow.

Orana Engineering conducted analysis using isothermal flow equations with a selection of these then verified via hydraulic modelling. Conclusions from modelling identified maximum allowable pipe lengths and flow rates for optimal compressed air flow, with subsequent improvement recommendations provided to the client.

Raw water pressure problems within the longwall and development mining areas at Xstrata Coal's Oaky No.1 Underground Coal Mine had resulted in numerous production delays. At the client’s request, Orana Engineering undertook a Life of Mine (LOM) study to develop a raw water supply plan based on strategic booster pump positioning. 

Hydraulic modelling was subsequently completed by Orana Engineering based on the Raw Water Supply Network LOM Study and taking into account the effects of firefighting demand pressures, flow rates and water hammer.

Results were summarised in a pump positioning flow sheet and a pump positioning plan to illustrate recommended current and future booster pump positions required to achieve minimum raw water supply pressures and flow rates. 

The main substation at Glencore’s Oaky Creek Coal is essential for surface operations.  Site personnel had highlighted multiple projects for implementation to collectively improve the integrity and reliability of the main sub. For each of the projects there were common elements and beneficial outcomes for executing them concurrently.

Given the critical nature of the projects and the importance of success, Orana Engineering developed a project management and design scope for provision of a dedicated Electrical / Control Systems Engineer from its Engineering Team.

Projects under the scope consisted of safety and reliability upgrades for OCC Main 66 / 11kV substation including automated racking of circuit breakers, interlocking of transformer tap changers and parallelling control, cable pit sump pump control. 

Work undertaken included detailed design, PLC and DCS configuration, protection relay configuration, racking controllers, and commissioning whilst also mananging the client's drawing management system.

Glencore planned to install the CAT MineStar Terrain Office system at its Oaky Creek Coal Mine to support GPS positioning and live maps in CHPP stockpile dozers.  As part of the upgrade, mine infrastructure and dozers required hardware installation to connect the dozers to the site network and enable communication with MineStar servers. In line with other Glencore sites, it was chosen to implement a Rajant wireless network to cover stockpiles and provide connectivity between dozers and the network. 

Orana Engineering was engaged to provide electrical and Operational Technology (OT) engineering design, configuration and drafting support for the CAT MineStar GPS implementation including preparation of three new virtual servers for various applications. Orana Engineering electrical engineers developed a scope of work which provided an overview of the onsite electrical installation works required to be carried out by others with supply, installation, testing and commissioning project managed by an Orana Engineering electrical and control systems engineer.

Due to the existing system not being compliant to site standards, BMA Saraji Mine had constructed a new reagents system for the supply of diesel and MIBC into their CHPP. Following construction, several attempts were made to wet commission the system however these were unsuccessful due to multiple problems identified by the client. 

Orana Engineering was requested to undertake a complete design review of the reagents system, to outline problems with the design and to provide a scope of work to rectify these such that wet commissioning could be completed.

At the conclusion of the review a bill of materials for the commissioning scope of work was provided, detailing procurement specifications for required mechanical equipment and spares.

The layout of the Rotary Breaker Reject Facility at Glencore's Collinsville Open Cut Coal Mine required loaders to be fully articulated to access and remove material from the reject bin.  Orana Engineering provided a proposal for re-orientation of the facility 90 degrees, allowing loaders to drive directly into the bin area for removal of material.  

The aim of proposed changes was a reduction in safety risks posed by awkward positioning of the facility. The design scope included modifying the existing reject chute to reduce blockages and other operational issues.  The new design allowed for greater clearance of reject material and with the chute supported off the side wall of the facility to ensure structural integrity.

Orana Engineering designers prepared a 3D model considering limited vehicle interactions, optimising loading operations and minimising risks of structural damage.  IFC drawings and project management were provided to complete the installation through to commissioning.

Process engineering personnel at Glencore’s Oaky Creek coal mine identified a need for review and gap analysis of existing coal sampler PRT (Production Resources / Tools) SAP documents, to determine where these differed from the recommendations of the original equipment manufacturers (OEMs) and from the PRTs of other Glencore sites.  

The assistance of Orana Engineering was sought in conducting the review and documenting differences or gaps identified, for further discussion with site engineering contacts. Outcomes from the analysis were documented in the form of a Gap Analysis Register for client review.

With client approval, revised or additional PRT’s were developed by Orana Engineering as required to close all gaps, with changes then presented to the client to determine any final modifications to be made prior to handover.

At the request of Glencore Collinsville Coal Mine, Orana Engineering performed engineering design and drafting for a new monorail to be installed within the CHPP secondary spirals area. Orana Engineering’s assistance with the project included SpaceGASS modelling of the area and completing initial engineering and analysis for the proposed monorail while considering any effects on the existing structure and performing calculations and structural design checks to Australian Standards AS4100, AS1170 and AS1418.18. 

Lifting vendors were consulted for monorail trolley and chain block options which ensured the most appropriate selections for the Collinsville application. 

The designers at Orana Engineering produced a 3D model which was issued to the client for review and feedback. The monorail was fabricated and installed by others to Orana Engineering detailed design drawings and then load tested with subsequent deflection results meeting the requirements of Australian Standards.

At the request of Carborough Downs Coal, Orana Engineering initiated the design of a new bin for collection of used coal samples within the CHPP. Up until that point practice had been to transport samples to the bin by wheelbarrow, with the barrow then lifted (rather than levered) and the contents tipped into the bin.

Carborough Downs requested that Orana Engineering design a bin to enable wheeling of the barrow into the bin such that the contents could be tipped without the need to lift the barrow. Once full the bin would be collected via a telehandler and emptied onto the rejects pile.

Orana Engineering designers prepared a high level 3D model of the proposed telehandler bin, a 3D design of the lifting and pivot mechanism and bin fabrication, detail and assembly drawings with RPEQ Supervision.

The Terminal Dam pump station at Glencore’s Oaky Creek coal mine is critical in supplying the mine and township of Tieri with raw water. The existing pump station had been in service for over 30 years during which time the electrical reticulation equipment had regular maintenance but no significant upgrades. Obsolete components, changes in Standards and degradation of the equipment all signaled that the HV supply, LV MCC and LCU’s was apporaching its end of service.

At the request of Oaky Creek Coal, Orana Engineering undertook offsite electrical and control system engineering and design drafting for a Terminal Dam HV upgrade and MCC replacement. An update of the Electrical Installation SOW for the modification at Terminal Dam was prepared prior to attending site to complete the configuration and assist with project management of installation and commissioning works.  

Orana Engineering was called upon by Glencore's Collinsville Open Cut Coal Mine to provide engineering, drafting and project management for an upgrade to its tertiary crusher and supporting structure, involving multiple site visits to assist with on-site aspects of the construction phase.  

The basis of design included engineering and drafting to understand and develop the FEED and scope for the capital project, designing of the support structure to install the replacement tertiary crusher and provision of package management for the entirety of the project.

Some of the primary deliverables for the project included 36x IFA / IFC drawings for the tertiary crusher structure upgrades, a critical spares list (including liaison with vendor), fabrication scope of work for tendering, a Change Management document, and a Risk Assessment.

Orana Engineering assisted Glencore's Clermont Coal with an engineering review of the structural integrity of head end support stools connected to its train load-out (TLO) bin ring beam as material build-up at the top of the bin cone had resulted in corrosion of several lower stools connected to the ring beam. Orana Engineering presented recommendations for temporary stiffening solutions and a repair methodology to restore conveyor supports to original design capacity.

Following the initial review, Clermont Coal requested that Orana Engineering undertake a further structural review of the TLO bin to analyse the effect of scaffold arrangements to be constructed on the bin and to confirm overall structural integrity with the additional applied loads.

Orana Engineering design drafters developed a concept design 3D model of proposed bracing including finite element analysis (FEA), and RPEQ certified detailed drawings for TLO column repairs were also delivered to the client.

The Village Kitchen at Glencore’s Hail Creek Mine camp was scheduled for upgrade with Orana Engineering engaged to provide engineering support for electrical, civil and building works, including a new shed.  A site visit was conducted to determine the scope of the upgrade and to collect site information comprising photos, drawings, measurements and location of water and gas services.

From the information gathered, Orana Engineering provided engineering design and project management of the Village Kitchen upgrade including a new shed distribution board, concrete slab, layout and connection of services to the new shed and prepared a detailed scope of work document for tendering purposes.

Orana Engineering design drafters produced RPEQ certified GA and concrete drawings showing details of services to be relocated, a slab and loading dock drawing, a new single line diagram for the distribution board, and revisions to existing distribution board drawings.

Glencore’s Collinsville Open Cut Mine engaged Orana Engineering for assistance with engineering design of a new concrete slab to allow for driving, loading / unloading of forklifts and delivery trucks at its warehouse building. The design accounted for tie-ins to existing slabs and a surrounding security fence with cantilevered sliding gates on western and eastern sides of the area.

Orana Engineering’s involvement comprised gathering of additional site data and drawings on existing slabs, reviewing geotechnical and ground survey data for conditions in the area, liaison with the client and plumbers etc to confirm area runoff and underground services, as well as engaging vendors of precast concrete barriers, sliding gates and mesh fencing.

Preliminary sketches for client review and discussion were produced by Orana Engineering’s design drafting personnel, followed by concrete general arrangement and detail drawings and a structural detail drawing ‘issued for construction’ with RPEQ Supervision.

Glencore's Collinsville Open Cut Coal Mine requested the assistance of Orana Engineering in conducting 3D laser scanning of its stockyard mobile equipment comprising raw, clean and bypass coal stackers as well as a raw coal reclaimer. 

Scanning was carried out during a four day shutdown, utilising Orana Engineering's Faro 3D Laser Scanner. Upon return from site, post-processing of files was completed and scan data prepared for issue to the client.

At the conclusion of the assignment, scan data was provided in a format suitable for interrogation by others in 'issued for use' format.

Oaky Creek Coal engaged Orana Engineering to perform electrical and control system design aspects of a 22M Flyover Conveyor to provide an interface between two existing conveyor systems.

Orana Engineering’s brownfield engineering expertise was drawn upon to resolve complexities in interfacing two different coal streams, powered from separate substations and controlled from independent process control systems. Should one system need to be shutdown it was necessary that the other system was not impacted.

The electrical engineering scope included powering the conveyor and transfer systems and providing lighting designs and power distribution. Control system engineering included selection and specification of instrumentation, specification of control system hardware and development of a functional specification.

Engineers at Glencore’s Oaky No. 1 underground coal mine engaged Orana Engineering to determine civil work requirements to install tripper equipment on the MG32 longwall conveyor. On completion of chamber mining, finished surfaces (rib and floor) may require modification for the installation of conveyor tripper equipment. The civil design must determine concrete grades for drainage, safe access and reinforcing for conveyor equipment, while minimising trimming and concrete required.

Manipulating “as-cut” survey data using AutoCAD, Orana Engineering design staff could accurately determine where tripper equipment could be installed with minimal trimming and concreting. A drawing set was produced detailing civil aspects of the tripper design, including chamber trimming, equipment mounting locations, configuration of reinforcing and relative concrete levels for drainage.

Orana Engineering was requested to complete an audit of water and wastewater services at BMA’s Blackwater Mine.  The audit was to determine whether new go-line infrastructure would adversely impact the existing mine industrial area services, and whether additional infrastructure or upgrades were required.

Data collected from site by Orana Engineering was used to prepare a hydraulic model for each service. Modelling results, findings and recommendations were included in a detailed report outlining the capacity and utilisation of existing services to quantify available system capacity for the proposed new buildings. Additionally, Orana Engineering’s drawing revision services were utilised to formally revise site P&IDs to As Built, incorporating mark-ups made during the site visit.

Due to expanding operations, Glencore's Oaky North underground operations saw benefit in having an underground workshop and refueling stations to reduce vehicle travel times and increase efficiencies. Orana Engineering was engaged to provide concept design and estimating assistance for project approval.

From communications with our client, Orana Engineering prepared concept general arrangement drawings for consideration. Based on these concept design drawings, a project capital estimate and project schedule were prepared for Oaky North.

From the information presented by Orana Engineering, the client could accurately consider whether the underground workshop was feasible and ensure that appropriate budgeting and project planning was completed at the concept design phase to improve confidence in the project prior to execution.

At Glencore’s Oaky No.1 underground coal mine, transportation of vast quantities of coal over long distances requires significant power. Often drive-head power is insufficient or constrained by allowable belt tension and an additional drive or power source is required to meet operating capacity. Additional power is commonly sourced from a driven conveyor tripper installed along the conveyor with appropriate excavation for the tripper.

Using the client’s existing mine plan to position the new tripper chamber, Orana Engineering design drafting personnel worked with site engineers to assess required chamber dimensions while simultaneously minimising the excavation of material.

Orana Engineering used AutoCAD to produce a drawing set detailing the mining required, and an overlay showing future equipment installations within the new chamber.

For personnel safety and compliance with Queensland’s Coal Mining Safety & Health Regulation it is a requirement for mine sites to provide electrical workers with access to up-to-date drawings for electrical equipment and electrical installations.

To improve the maintainability of plant electrical systems and personnel safety, Hail Creek Mine engaged Orana Engineering to create bound books of electrical drawings for Draglines 1 and 7 and Shovel 14. Multiple books were made for each machine in both A4 and A3 sizes and using waxed (waterproof) paper to ensure longevity.

Using vendor drawings from the client, Orana Engineering produced bound books containing all electrical power, control and termination diagrams associated with the respective mobile plant.

Carborough Downs Coal Underground Mine had transitioned from a bord and pillar mining system to longwall. The result was a need to upgrade capacity of the coal clearance conveyor system.  Orana Engineering was engaged to provide Client Engineering assistance to deliver underground conveyor equipment to meet the longwall production schedule.

Orana Engineering monitored vendor design progress against the schedule, performed design reviews to ensure correction of errors prior to final client approval, monitored and managed fabrication and delivery schedules and managed budget and variations in line with the contract.

By co-ordinating with the client’s installation group and managing the vendor in line with the client’s schedule, the conveyors were successfully installed and made available for longwall production.

Since 2005, Orana Engineering has provided 24/7 support for Glencore's Oaky Creek Coal control systems. At the CHPP a Yokogawa DCS installed in 1998 is used as the primary control system. With existing CentumCS Unix software no longer supported by Yokogawa, it was essential to complete an upgrade to the CentumCS3000 system.

Orana Engineering developed conversion tools to allow configuration data to be extracted from the CentumCS Unix platform and imported into the CentumCS3000 environment. These tools provided efficiency and accuracy for the conversion and delivered a significant cost saving.

The quality of conversion tools and simulation programs developed by Orana Engineering resulted in highly efficient site commissioning, completed without plant downtime.